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Comparing Traditional and Integrated Rod-Style Linear Actuators

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Comparing Traditional and Integrated Rod-Style Linear Actuators How roller-screw and ball-screw actuators compare in high-force applications: As electric rod-style actuators overtake fluid power in a variety of high-force applications, it is important to understand how different screw technologies compare in the search for optimum performance and low life-cycle cost. Electric rod-style screw actuators are replacing fluid power in high-force applications throughout industry. Tasks once limited to hydraulic and pneumatic cylinders such as pressing, holding, lifting and spot welding are now being performed by electric actuators that offer lower life-cycle costs. Hydraulic and pneumatic cylinders still have their place, but electric actuators have numerous performance advantages in high-force applications up to and exceeding 50,000 lbf. Some of these advantages include a smaller footprint; a long and more predictable life; lower life-cycle costs; greater accuracy, control and flexibility; lower maintenance; faster change-over and setup; lower energy use; and less environmental impact. In general, screw mechanisms provide the means to produce linear motion by the rotation of either the screw or nut in an assembly. The screw is a cylindrical element that has threads; the nut is a matching component that rides on the screw. Each component is capable of rotating independently upon the other. Linear motion occurs by restraining one element. Tolomatic is a leading supplier of electric linear actuators. Tolomatic’s In high-force applications, two types of screw technologies are typically used in electric 60+ years of expertise covers a wide rod-style actuators: ball screws and roller screws. Actuators with ball screws and roller range of industries and linear motion screws are now able to achieve extremely high forces, making them suitable for many applications. applications previously dominated by fluid power devices. What’s more, the speed, accuracy and flexibility of electric actuators create the potential for increased production throughput, process and yield improvements, as well as more adaptable machines. Copyright ©2020 Tolomatic, Inc. How roller-screw and ball-screw actuators compare in high-force applications www.tolomatic.com 763-478-8000 1 9900-4060_01_WP_RollerVSball Screw mechanisms provide the means to produce linear motion by the rotation of either the screw or nut in an assembly. Electric rod actuators have numerous performance advantages in high-force applications. Shown: Tolomatic electric actuators (clockwise from top left): ERD, RSA, RSX, IMA, ServoWeld®. Ball-screw actuators Ball-screw actuators typically have efficiencies around 80 percent. Ball screws are ideal for low-duty-cycle applications with moderate force requirements and moderate to high speeds. A ball screw’s ball bearings have fewer points of contact than roller screws, resulting in a lower life expectancy. Ball screws utilize a thread form that has a circular shape. The nut has a matched thread form, allowing ball bearings that fit between the grooves to transmit force and relative motion with high efficiency. Ball-screw actuators typically have efficiencies around 80 percent. Copyright ©2020 Tolomatic, Inc. How roller-screw and ball-screw actuators compare in high-force applications www.tolomatic.com 763-478-8000 2 9900-4060_01_WP_RollerVSball The ball bearings are allowed to roll and recirculate through one of several circuits in the nut as rotation and linear motion occurs. There are several designs of ball screw nuts that differ in the number of ball circuits and how the ball recirculation path is controlled. The ball bearing path is a critical factor in determining the maximum speed potential of the mechanism. Alternative designs, such as internal paths or end returns, offer minor advantages such as increased velocities or reduced operating noise. However, most ball nut designs function similarly. Ball screws are available in a wide variety of diameters, leads and accuracies with both metric and imperial lead designs. A grade system was defined to classify the lead accuracies of ball screws and is regulated by ISO-3408. Ball screws are now commonly available in five grades that range in accuracy from 6 micrometers per 300 millimeters (0.0002 inches per foot) to 210 micrometers per 300 millimeters (0.0080 inches per foot). Roller-screw actuators Actuators with roller screws A roller-screw thread form is generally triangular in shape and transmits force through typically range from 75 a matched set of multiple threaded rollers in the nut. These rollers are allowed to rotate to 80 percent efficiency, within the nut while contacting the thread form of the screw. The roller nut has a set slightly lower than the number of rollers that provide significantly more contact points with the screw in the same efficiency of a ball screw. space compared to ball nuts, resulting in very high force transmission capabilities and much longer life compared to ball screws of similar diameter. Like ball screws, roller screws have a good efficiency rating because they are designed with rolling elements as compared to the sliding elements of an Acme screw. Due to the increased areas of contact, actuators with roller screws typically range from 75 to 80 percent efficiency, which is just slightly lower than the efficiency of a ball screw. Roller screws, like ball screws, are produced within the ISO-3408 grade system so they share similar lead accuracy considerations. Standard roller screws are hardened before being precision ground, resulting in a much deeper hardness and the highest Dynamic Load Rating (DLR) of all the roller screw types. Another type of roller screw – the inverted planetary roller screw – operates in much the same way as a standard roller screw, except the functions of the nut and screw are reversed – that is, the rollers move inside the nut. Roller screws have greater force transmission capabilities since the rollers have increased contact with the screw threads, resulting in improved distribution of force. They deliver high force, operate at high speeds, are long lasting and require little maintenance. Copyright ©2020 Tolomatic, Inc. How roller-screw and ball-screw actuators compare in high-force applications www.tolomatic.com 763-478-8000 3 9900-4060_01_WP_RollerVSball Actuators with ball or roller screws share a number of advantages over fluid power in high-force applications. These include higher energy efficiency, better accuracy & repeatability and the potential for process improvements that can increase throughput and lower unit costs. An inverted roller screw operates similar to a standard roller screw; however, the functions of the nut and screw are reversed. The rollers traverse inside the nut. Shared advantages of actuators with ball and roller screws in high-force applications Actuators with ball or roller screws share a number of advantages over fluid power in high-force applications. These include higher energy efficiency, better accuracy and repeatability, smaller overall system footprint, quiet operation, low environmental impact, reduced maintenance, lower life-cycle costs, and the potential for process improvements that can increase throughput and lower unit costs. • Higher energy efficiency – Electric actuator systems typically operate in the 75- to 80-percent efficiency range. In comparison, pneumatic systems typically range from 10 to 25 percent efficiency. Hydraulic systems typically range from 40 to 55 percent efficiency. Many factors affect fluid power efficiencies, including temperature, seal integrity, leaks and many others. One significant factor is that electric actuators only demand current to the drive motor when it is required. When at rest, electric actuators require very little current to hold their positions. On the other hand, fluid- powered actuators require the fluid medium to be pressurized at all times by power units or compressed systems, resulting in an inefficient use of power. Over time, power savings add up. • Better accuracy and repeatability – In applications requiring precise control of motion and position, actuators with electric ball screws or roller screws offer significant advantages. Standard fluid actuators are good for end-to-end position applications, but mid-stroke positioning is more complicated, requiring a control valve and operator assistance. More advanced servo hydraulic control systems give fluid systems greater precision and repeatability, but at a considerable increase in cost and complexity. Electric actuator systems are much less complex and, once programmed, require little intervention or maintenance. • Quiet operation – A noisy power unit running a fluid cylinder can be a noise polluter for any operator near the machine. Copyright ©2020 Tolomatic, Inc. How roller-screw and ball-screw actuators compare in high-force applications www.tolomatic.com 763-478-8000 4 9900-4060_01_WP_RollerVSball • Low environmental impact – Leaks from hydraulic systems can create messes in In pneumatic systems, air leaks the manufacturing environment and also present a safety hazard if someone slips on create unwanted noise and the spill. In pneumatic systems, air leaks create unwanted noise and waste energy. waste energy. In addition, hydraulic leaks can cause serious contamination to key processes and products – such as food processing, pharmaceuticals, medical devices and others. Electric actuator systems share none of these drawbacks. • Smaller system footprint – Not only do electric actuator systems save energy, they also save space. Hydraulic systems require
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